Apparatus for obtaining rounded filter plugs for cigarettes

ABSTRACT

The filter plug roller is formed by a pressure applying rotating roller and a holder having two inserts. The roller and inserts define a passageway for the filter plugs in which the first insert is more closely spaced to the roller than is the second insert so as to cause deformation of the filter plugs during rolling of the plugs over the first insert. The second insert is spaced from the roller at a distance equal to the diameter of the filter plug so as to cause a gentle rolling of the filter plugs out of the apparatus. The first insert serves to deform the relatively stiff papers used in enveloping the filter media of the filter plug while the second insert serves to impart a substantially perfect roundness to the filter plug.

United States Patent [191 Van Hall 1 Mar. 26, 1974 APPARATUS FOROBTAINING ROUNDED Primary Examiner-R0y Lake FILTER PLUGS FOR CIGARETTES[75] Inventor: Floyd Van Hall, Durham, NC.

[73] Assignee: Liggett & Myers Incorporated, New

York, N.Y.

[22] Filed: Dec. 4, 1972 [21] Appl. No.: 311,565

[52] U.S. Cl. 93/1 C, 131/94 [51] Int. Cl B30b 3/02 [58] Field of Search93/1 C, 1 G, 1 WZ, 77 FT, 93/83; 131/94 [56] References Cited UNITEDSTATES PATENTS 2,857,722 lO/l958 Smith 131/94 UX 3,164,243 1 H1965Rudszinat et a1. 93/1 C 2,809,640 10/1957 Oldenkamp 131/94 Reilly, Carr8!. Chapin [5 7] ABSTRACT The filter plug roller is formed by a pressureapplying rotating roller and a holder having two inserts. The roller andinserts define a passageway for the filter plugs in which the firstinsert is more closely spaced to the roller than is the second insert soas to cause deformation of the filter plugs during rolling of the plugsover the first insert. The second insert is spaced from the roller at adistance equal to the diameter of the filter plug so as to cause agentle rolling of the filter plugs out of the apparatus. The firstinsert serves to deform the relatively stiff papers used in envelopingthe filter media of the filter plug while the second insert serves toimpart a substantially perfect roundness to the filter plug.

16 Claims, 7 Drawing Figures PAIENIEDums mm 3799 041 sum 1 or 2APPARATUS FOR OBTAINING ROUNDED FILTER PLUGS FOR CIGARETTES Thisinvention relates to an apparatus and method for obtaining roundedfilter plugs for cigarettes.

Heretofore, in the manufacture of filter cigarettes made of a filter anda tobacco column, it has been known to manufacture the filter separatelyfrom the tobacco column. Generally, the filters have been made in theform of a filter plug of a length to supply filters for six or morecigarettes. Such filter plugs have, in turn, been made from a continuousrod of filter material which is served into the composite filter pluglengths. ln forming such a filter rod, the filter media has beenenveloped in a travelling strip of paper, commonly referred to asmouthpiece or filter paper. This paper has usually been delivered in aflat condition to receive the filter media and has thereafter beenfolded over the filter media with a seam being formed on the overlappingedges of the paper by various techniques. In many cases, during theformation of the seam, the filter plug has been deformed, for example,into an oblong crosssectional shape due to the forces required forseaming. As a result, the resultant filter plugs have also been of adeformed shape.

Since a deformed filter plug is usually not suitable for application toa tobacco column of round shape for the manufacture of a filtercigarette, the filter plugs have been subjected to various roundingtechniques. For example, it has been known to pass the filter plugsindividually through a confined path in which the filter plugs can berolled into a round shape. For such a purpose, it has been known to usea plug roller formed of a press roller and abed plate-like structurehaving a curvilinear surface conforming to the shape of the roller andspaced a distance from the roller equal to the diameter of the filterplug. Such a structure serves to receive and roll the filter plugbetween the roller and plate-like structure so as to smooth out thedeformed shape of the filter plug into a rounded cross-sectional shape.

However, in the case where a filter for a filter cigarette is made ofmulti-filter media, for example, where a granular adsorptive filtermaterial such as charcoal has been sandwiched between two sections offibrous entrainment filter material such as cellulose acetate, thefilter plugs for which these filters are made have not been adequatelyrounded in the conventional plug rollers. This has been found to becaused, in part, by the use of one layer of plug wrap paper forenveloping the fibrous filter media sections and the use of a secondlayer of mouthpiece paper for enveloping both the wrapped fibrous filtermedia sections and the granular filter media sections. In addition, thestiffness of the papers has been such as to resist the deformationforces of the plug roller so that the filter plug does not respond tothe rolling action imparted by the plug roller.

Accordingly, it is an object of this invention to provide a technique ofrounding filter plugs made with relatively still paper.

It is another object of this invention to provide a technique ofrounding multi-filter media filter plugs for cigarettes.

It is another object of this invention to provide a plug roller ofsimple construction for rounding filter plugs in an economical fashion.

It is another object of this invention to provide a technique ofrounding filter plugs made with multiple layers of paper.

Briefly, the invention provides an apparatus and method for roundingfilter plugs for cigarettes. The apparatus is constructed with apressure applying means having an endless movable surface, a firstsurface means having a friction surface spaced a first distance from thepressure applying means of a magnitude less than the diameter of afilter plug to cause a deformation of the filter plug during rolling onthe friction surface, and a second surface means having a frictionsurface spaced a second distance from the pressure applying means ofgreater magnitude than the first distance and of a magnitude equal tothe diameter of a filter plug to cause rolling of the filter plug. Thepressure applying means serves as a drive to move the delivered filterplugs over the respective surfaces of the two friction surface means. Inaddition, the narrower spacing between the pressure supplying means andthe first surface means allows the filter plug to be positively deformedso as to overcome the resistance of the filter papers of the plug todeformation while at the same time removing any residual forces in thefilter plug which would cause a return to the deformed state. Forexample, the distance between the first surface means and the pressureapplying means can be 1/16 inch less than the nominal diameter of thefilter plug. The distance between the second surface means and thepressure applying means permits the deformed filter plug to expand underits normal resiliency while being gently rolled into a truly roundcross-sectional shape.

In one particular embodiment of the invention, the pressure applyingmeans is in the form of a pressure roller having a resilientlydeformable rubber cover thereon while the two surface means are in theform of insert members which are placed within a holder and which areeach provided with a roughened curvilinear frictional surface, forexample, a serrated surface.

In order to provide a smooth transition between the insert members, thesurface of the first insert member is provided with an arcuately curvedforward or first portion and a tapered tail or second portion while thesurface of the second insert member is formed with an arcuate portioncontiguous to the tapered surface of the first insert member. Also, thetapered surface-of the first insert member terminates at a pointslightly higher than the initial point of the second insert member whileproviding a continuous surface therewith. In addition, the curvilinearsurface of the two insert members are each formed on a radiuscorresponding to the radius of the roller.

The method of the invention resides in the step of moving a formedfilter plug through a passageway having a first portion sized of amagnitude less than the diameter of the formed filter plug to causedeformation and rolling of the filter plug through the first portion,and a second portion sized of a magnitude greater than the first portionand equal to the diameter of the formed filter plug to cause rolling ofthe filter plug through the second portion.

These and other objects and advantages of the invention will become moreapparent from the following de tailed description and appended claimstaken in conjunction with the accompanying drawings in which:

FIG. 1 illustrates a schematic view of a machine for making multi-filtermedia filter plugs;

FIG. 2 illustrates a fragmentary view of a portion of a filter rodwithin the machine of FIG. 1;

FIG. 3 illustrates a view taken on line 33 of FIG.

FIG. 4 illustrates an exaggerated cross-sectional view of a filter plugmade on a machine as shown in FIG. 1;

FIG. 5 illustrates a cross-sectional view of an apparatus according tothe invention;

FIG. 6 illustrates a view taken on line 66 of FIG. 5; and

FIG. 7 illustrates a cross-sectional view ofa filter plug which has beenrounded by the apparatus as shown in FIGS. 5 and 6.

Referring to FIG. 1, a machine 10 for making filter plugs 11 is ofgenerally known construction and includes a conveyor system 12 forreceiving a supply of fibrous filter media 13, such as tow, from asource at one end, a tube 14 for gathering and forming the tow into acylinder and a supply means 15 for supplying a continuous strip of plugwrap paper 16 for enveloping the tow to form a plug rod 18. In addition,a suitable means is provided to fold the longitudinal edges of the plugwrap paper 16 about the tow cylinder and a seam sealer 17 is provided tooverlap and seal the longitudinal edges of the plug wrap paper 16 toform a longitudinal seam. The machine 10 also includes a knife assembly19 which serves to sever the plug rod 18 into sequential spaced apartplugs 20 and a conveyor system 21 downstream of the knife assembly 19 toreceive and convey the individual plugs 20 on a travelling web 22 ofmouthpiece paper supplied from a supply means 23. This mouthpiece paper22 can be of lighter weight and thinner thickness than the plug wrappaper 16. As shown, the mouthpiece paper 22 is'delivered from a supplyroll 23 over a plurality of suitable guide rolls 24 and is positioned onthe conveyor 21 so as to convey the filter plugs 20 under a granulatedfilter media dispensing apparatus 25 as is known. In addition, agarniture section (not shown) is provided in which the mouthpiece paper22 is sequentially formed into a U- shape to receive the granulatedfilter material and thereafter enveloped over the filter plugs 20 aregranulated filter media 26 in a tube-like cylinder with overlappingedges 27 (see FIG. 3).

Referring to FIGS. 1 and 3, a seam sealer 28 of generally knownconstruction is positioned downstream of the dispensing apparatus 25 toseal the overlapping edges 27 of the mouthpiece paper 22 to each other.For example, the seam sealer 28 includes a heater bar 29 which ismounted over the travelling assembly of mouthpiece paper 22 and filtermedia. This seam sealer 28 applies heat and pressure to the mouthpiecepaper 22 in the area of the overlapped edges 27 to effect a longitudinalseam seal and to form a continuous filter rod 30. A suitable guide (notshown) can also be pro vided to shape the conveyor ribbon 31 into arounded shape to act as a backup for the heater bar 29.

Referring to FIG. 1, the filter rod is conveyed to a single knife cutter32 which is timed to sever the filter rod 30 into equal lengths offilter plugs 11, each made up of a multisectional construction (see FIG.2), for example, to provide two or more filters. These filter plugs 11are then pushed by the plugs behind as well as by the rod 30 through aheat sealing apparatus 33, for example, as described in US. Pat.application Ser. No. 268,816 filed July 3, I972.

Referring to FIG. 5, after the plugs 11 leave the heat sealing apparatus33, each is deposited onto a ramp 34 which is downwardly inclined so asto deliver each plug 11 to a plug roller 35.

Referring to FIG. 4, as a filter plug 11 passes out of the machine 10,the plug 11 may have a deformed shape from a rounded, i.e. circular,cross-sectional shape. For purposes of exaggeration, the filter plug 11is shown with an oblong shape with the longitudinal seam shownflattened.

Referring to FIGS. 5 and 6, the plug roller 35 includes a rotatableroller 36 provided with a resiliently deformable rubber cover 37 and aholder 38 below the roller 36 which has a recess 39 receiving a pair ofinsert members 40, 41.

Referring to FIG. 6, the roller 36 is fixedly mounted on a shaft 42which carries a pulley 43 at one end so as to be driven in a suitablemanner by a drive source (not shown). The shaft 42 is journalled withinsuitable anti-friction bearings 44 near each end which bearings 44 aremounted within upstanding legs 45 secured to the holder 38 so as to fixthe roller 36 in a preset position.

Referring to FIG. 5, the inserts 40, 41 which can be of any suitablematerial such as steel or other metal are each provided with africtional surface 46, 47, for example, a serrated surface, inopposition to the surface of the roller 36. In addition, the surface 48of the first insert 40 is provided with a first portion A which isdisposed on a radius substantially equal to the radius of the surface ofthe cover 37 on roller 36 as well as with a second portion B which istapered away from the roller 35 towards the second insert 41. Thesurface 47 of the second insert 41 also has a curvilinear surfacecorresponding to the radius of the surface of the cover 37 and to thesurface portion A of the first insert 40.

The surface 46 of the first insert 40 is spaced from the surface of therubber cover 37 of the roller 36 by a distance which is of a magnitudeless than the diameter of a filter plug 11, that is, the nominaldiameter of the filter plug 11. For example, for a filter plug having adiameter of inch, the distance between the insert member 40 and thecover 37 of the roller 36 is 5/16 inch. The surface 47 of the secondinsert member 41 is spaced from the roller 36 and the cover 37 by adistance substantially equal to the diameter of the filter plug and istherefore of a magnitude greater than the distance between the firstinsert 40 and the roller 36.

The edge of the first insert member 40 contiguous to the second insertmember 40 is of slightly greater height than the contiguous edge of thesecond insert member 41 so as to provide a small step therebetween.

For purposes of illustration, the dimensions of the insert members areas follows. The first insert member 40 is of a length of 2 inches whilethe curvilinear portion A is of a length of 1% inches with a radius of2% inches and a height at the initial end of 0.690 inches. The taperedportion B tapers from a height or thickness of 0.178 inches to 0.160inches at the edge of the member 40. The second insert member 41 is of alength of 1% inches with the curvilinear surface 47 being formed of aradius of 2% inches. In addition, the thickness of the second insertmember at the forward edge is 0.155 inches and at the tail edge is 0.650inches. Both insert members 40, 41 are provided with serrations disposedwith sidewalls at an angle of 60 and of a length of 0.050 inches and athroat width of the same length as a sidewall.

In forming the insert members 40, 41 each can be machined at the sametime provided a shim plate is placed under the smaller member 41 tobring the memher up to the correct radius.

Referring to FIG. 5, the holder 38 is provided with a bevelled edge 48adjacent the recess 39 which begins at a point contiguous to the tailedge of the second insert member 41 to provide a small continuous exitsurface for a filter plug 11. The holder 38 also cooperates with a guideramp 49 down which a rounded plug 11 can roll and a grooved deliveryroller 50 which individually receives a filter plug 11 and transfers thefilter plug into a suitable catcher 51.

The plug roller 35 can also be provided with a pneumatic device adjacentthe delivery ramp 34 so as to facilitate entry of the filter plugs 11into the passageway formed between the roller 36 and the insert members40, 41 in a straight manner, i.e. parallel to the axis of the roller 36.In this respect, a conduit 52 is placed near the bottom of the ramp 34so as to direct a continuous stream of air across the bottom of the ramp34 into the passageway. In addition, the ramp 34 can be inclined in amanner so that the filter plugs 11 drop under gravity to a point on theholder 38 adjacent the entry to the passageway between the roller 36 andinsert members 40, 41. A recess (not shown) can be formed in the holderat this point in a location corresponding to one end of a filter plug.This aids in aligning the filter plug in a straight manner before beingblown under the roller 36.

In operation, after a filter plug 11 has been made on the machine (FIG.1), the filter plug 11 is directed onto the ramp 34 (FIG. 5) fordelivery into the plug roller 35. Next, upon rolling down the ramp 34the plug roller is directed, as by the air stream of the conduit 52 intothe passageway between the rotating roller 36 and the insert members 40,41 in the holder 38. The filter plug 11 is then initially engaged by theroller 36, which is rotating in a counterclockwise direction as shown inFIG. 5, and rolled across the serrated curvilinear surface 46 of theinsert member 40. At the same time, due to the restriction of thepassageway, the plug 11 is deformed under a positive force. This causesthe stiffness of the mouthpiece paper 22 and the plug wrap paper 16 tobe overcome. Thereafter, the deformed filter plug 1 l is rolled acrossthe transition portion B of the insert member 40 wherein the deformationforce is relieved and rolled across the curvilinear surface 47 of thesecond insert member 41. In rolling across the surface of the secondinsert member 41, thefilter plug is driven by the roller 37 under agentle rolling force which effects a rounding of the filter plug intothe final rounded shape as shown in FIG. 7. Next, the filter plug isrolled away from the roller 36 across the bevelled edge 48 of the holder38. The filter plug 1 1 then rolls down the remainder of the holdersurface across the ramp 49 onto the delivery roller 50 from which thefilter plug 11 is then directed into the catcher 51.

It is noted that the papers 16, 22 used in making the filter plugs arerelatively thin compared to the diameter of the plugs and much thinnerthan as illustrated in the exaggerated FIG. 7 so that the finalcross-sectional shape of the plugs upon emanating from the plug roller35 is, for all practical purposes, a truly round circular shape both tothe naked eye and to the touch.

The invention thus provides a simple apparatus of relatively few partswhich is capable of rounding filter plugs into a truly roundcross-sectional shape against the resistance of the various papers andmaterials which are used in the formation of the filter plug.

The invention also provides a technique whereby the out of roundness ofa filter plug can be quickly and efficiently corrected.

What is claimed is:

1. An apparatus for obtaining rounded filter plugs for cigarettescomprising a pressure applying means having an endless movable surfacethereon disposed in a preset position;

a first surface means made of metal and having a serrated frictionsurface spaced a first distance from said movable surface of saidpressure applying means, said first distance being of a magnitude lessthan the diameter of a filter plug to cause a deformation of the filterplug during passage of the filter plug between said pressure applyingmeans and said first surface means; and

a second surface means made of metal and having a serrated frictionsurface spaced a second distance from said movable surface of saidpressure applying means, said second distance being of greater magnitudethan said first distance and of a magnitude equal to the diameter of afilter plug to cause rolling of the filter plug between said pressureapplying means and said second surface means after passage from saidfirst surface means.

2. An apparatus as set forth in claim 1 wherein said movable surface ofsaid pressure applying means is resiliently deformable.

3. An apparatus as set forth in claim I wherein said movable surface ismade of rubber.

4. An apparatus as set forth in claim 1 wherein said friction surface ofeach surface means is a roughened surface.

5. An apparatus as set forth in claim 4 wherein each said frictionsurface is a curvilinear surface.

6. An apparatus as set forth in claim 5 wherein said pressure applyingmeans is a rotatable roller.

7. An apparatus for rolling filter plugs comprising a rotatable pressureroller;

a first member having a roughened curvilinear surface spaced a firstdistance from said roller, said distance being of a magnitude less thanthe diameter of a filter plug to cause a deformation of the filter plugduring rolling passage of the filter plug between said roller and saidfirst member; and

a second member having a roughened curvilinear surface spaced a seconddistance from said roller, said second distance being of greatermagnitude than said first distance and of equal magnitude to thediameter of a filter plug to cause rolling of the filter plug betweensaid roller and said second member after passage from said first member.

8. An apparatus as set forth in claim 7 wherein said pressure roller hasa resilient deformable surface thereon in facing relation to saidmembers.

9. An apparatus as set forth in claim 7 wherein said surface of saidfirst member has a first portion of arcuate shape and a seconddownstream portion of tapered shape.

10. An apparatus as set forth in claim 9 wherein said surface of saidsecond member is of arcuate shape and extends from said tapered surfaceof said first member.

11. An apparatus as set forth in claim 10 wherein said second member isof a length less than said first memher and is of a height at theupstream end thereof slightly less than the height of said first memberat the downstream end thereof.

12. An apparatus as set forth in claim 7 wherein said members are madeof metal and said surfaces are serrated.

13. An apparatus as set forth in claim 12 wherein said pressure rollerhas a rubber surface in facing relation to said members.

14. An apparatus as set forth in claim 7 which further comprises aholder having a recess receiving said members therein in contiguousrelation to each other to form a continuous surface of said curvilinearsurfaces.

15. An apparatus as set forth in claim 14 wherein said holder has abeveled edge adjacent said recess and said second member to form acontinuous surface with said second member.

16. An apparatus for rolling filter plugs for cigarettes comprising arotatable roller;

a holder having a recess therein disposed below said roller;

a first insert member in said recess spaced a first distance from saidroller to rollably engage and deform a filter plug passing therebetween;and

a second insert member in said recess contiguous to said first insertmember and spaced a second distance from said roller to rollably engagethe filter plug passing therebetween, said second distance being of lessmagnitude than said first distance.

1. An apparatus for obtaining rounded filter plugs for cigarettescomprising a pressure applying means having an endless movable surfacethereon disposed in a preset position; a first surface means made ofmetal and having a serrated friction surface spaced a first distancefrom said movable surface of said pressure applying means, said firstdistance being of a magnitude less than the diameter of a filter plug tocause a deformation of the filter plug during passage of the filter plugbetween said pressure applying means and said first surface means; and asecond surface means made of metal and having a serrated frictionsurface spaced a second distance from said movable surface of saidpressure applying means, said second distance being of greater magnitudethan said first distance and of a magnitude equal to the diameter of afilter plug to cause rolling of the filter plug between said pressureapplying means and said second surface means After passage from saidfirst surface means.
 2. An apparatus as set forth in claim 1 whereinsaid movable surface of said pressure applying means is resilientlydeformable.
 3. An apparatus as set forth in claim 1 wherein said movablesurface is made of rubber.
 4. An apparatus as set forth in claim 1wherein said friction surface of each surface means is a roughenedsurface.
 5. An apparatus as set forth in claim 4 wherein each saidfriction surface is a curvilinear surface.
 6. An apparatus as set forthin claim 5 wherein said pressure applying means is a rotatable roller.7. An apparatus for rolling filter plugs comprising a rotatable pressureroller; a first member having a roughened curvilinear surface spaced afirst distance from said roller, said distance being of a magnitude lessthan the diameter of a filter plug to cause a deformation of the filterplug during rolling passage of the filter plug between said roller andsaid first member; and a second member having a roughened curvilinearsurface spaced a second distance from said roller, said second distancebeing of greater magnitude than said first distance and of equalmagnitude to the diameter of a filter plug to cause rolling of thefilter plug between said roller and said second member after passagefrom said first member.
 8. An apparatus as set forth in claim 7 whereinsaid pressure roller has a resilient deformable surface thereon infacing relation to said members.
 9. An apparatus as set forth in claim 7wherein said surface of said first member has a first portion of arcuateshape and a second downstream portion of tapered shape.
 10. An apparatusas set forth in claim 9 wherein said surface of said second member is ofarcuate shape and extends from said tapered surface of said firstmember.
 11. An apparatus as set forth in claim 10 wherein said secondmember is of a length less than said first member and is of a height atthe upstream end thereof slightly less than the height of said firstmember at the downstream end thereof.
 12. An apparatus as set forth inclaim 7 wherein said members are made of metal and said surfaces areserrated.
 13. An apparatus as set forth in claim 12 wherein saidpressure roller has a rubber surface in facing relation to said members.14. An apparatus as set forth in claim 7 which further comprises aholder having a recess receiving said members therein in contiguousrelation to each other to form a continuous surface of said curvilinearsurfaces.
 15. An apparatus as set forth in claim 14 wherein said holderhas a beveled edge adjacent said recess and said second member to form acontinuous surface with said second member.
 16. An apparatus for rollingfilter plugs for cigarettes comprising a rotatable roller; a holderhaving a recess therein disposed below said roller; a first insertmember in said recess spaced a first distance from said roller torollably engage and deform a filter plug passing therebetween; and asecond insert member in said recess contiguous to said first insertmember and spaced a second distance from said roller to rollably engagethe filter plug passing therebetween, said second distance being of lessmagnitude than said first distance.